Method of making dispensing containers having strong end closures



June 23, 1959 Original File BERGSTEIN KI DISP SIN ONG . F. D. METHOD OF- MA HAVING d Dec. 20, 1954 ET AL G CONTAINERS CLOSURES 3 Sheets-Sheet 1 I .FIBAZ f4 INVENTORS I'Temixfl BEEGSTEIN I @FREDB. umsmaJe,

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ATTORNEYS.

June 23, 1959 Original Filed Dec.

F. D. BERGSTEIN ETAL 2,391,453 METHOD OF MAKING DISPENSING CONTAINERS HAVING STRONG END CLOSURES v 20, 1954 '3 Sheets-Sheet 3 fic'za mmvrons.

ATTORNEYS.

United States Patent Ofice 2,891,453 Patented June 23, 1959 METHOD OF MAKING DISPENSING CONTAINERS HAVING STRONG END CL'OSURES Frank D. Bergstein, Hamilton, and Alfred B. Kleingers,

Jr., and Robert W. Nerenberg, Middletown, Ohio, assignors to Bergstein Packaging Trust, a trust composed of Robert M. Bergstein and Frank D. Bergstein, trustees Original application December 20, 1954, Serial No. 476,484, now Patent No. 2,791,364, dated May 7, 1957. Divided and this application August 17, 1956, Serial No. 604,804

8 Claims. (Cl. 93-391) This application is a division of our copending application Serial No. 476,484, filed December 20, 1954, which issued as Patent No. 2,791,364, granted May 7, 1957, and entitled Dispensing Containers Having Strong End Closures.

This invention relates to paperboard containers, and more specifically to procedures for assembling liquid tight containers having flat end closures one of which is provided with a pouring opening covered by a liftable flap formed as an integral part of the end closure.

In the copending application of Frank D. Bergstein, Serial No. 414,558, filed March 8, 1954, and entitled Containers Having Strong End Closures and Methods of Making Them, there is taught a container construction characterized by strong end closures at both ends of the structure, the arrangement of parts being such that positive sealing pressure may be applied to the end closures to effect the positive sealing of the parts thereof. Our aforementioned copending application Serial No. 476,484 relates to improvements in containers of the general character taught in the said Bergstein application and relates specifically to improved top closure constructions designed to enhance the strength of the top closure and improve its liquid tightness by effecting a more perfect seal between the various flaps making up the end closure.

It is a principal object of the instant invention to provide improved methods for assembling the container blanks of our copending application Serial No. 476,484 into erected and sealed container structures.

Yet a further object of our invention contemplates the erection and sealing of the end closure flaps by positive sealing pressure so as to effect a tight bond between the juxtaposed surfaces of the end closure flaps.

Still a further object of our invention is the provision of a series of manipulative steps eifective to erect and seal container blanks of the character disclosed in a novel and efiective manner which is readily suitable to mechanization for the high speed commercial productionof such containers.

These and other objects of our invention which will appear hereinafter or which will be apparent to the skilled worker in the art upon reading these specifications, we accomplish by that construction and arrangement of parts and by those procedures of which we shall now describe certain exemplary embodiments. Reference is now made 'to the figures of the drawings wherein:

Figure 1 is a plan view of a carton blank embodying a novel top closure in accordance with our invention.

Figure 2 is a partial plan view illustrating an alternative arrangement of closure flaps.

Figure 3 is. a plan view of the blank of Figure 1 in tubed condition.

Figure 4 is a perspective view illustrating exemplary means for effecting the initial folding of the top closure flaps.

Figure 5 is a perspective view illustrating a succeeding step in the folding of the top closure flaps.

Figure 6 is a partial vertical sectional view illustrating the application of pressure means to pre-form the upper end of the container body.

Figure 7 is a partial vertical sectional view similar to Figure 6 illustrating the pressure applying means in closed position.

Figure 8 is a partial perspective view illustrating the top of the container subsequent to the application of the pressure means.

Figure 9 is an enlarged fragmentary plan view of a corner of the container illustrated in Figure 8.

Figure 10 is a fragmentary perspective view illustrating the upper end of the container in fully assembled condition.

Figure 11 is a partial vertical sectional view taken along the line 1111 of Figure 10.

Figure 12 is a fragmentary vertical sectional view similar to Figure 11 taken along the line 1212 of Figure 10 with pressure applying means illustrated diagrammatically in dotted lines.

Figure 13 is a fragmentary perspective view similar to Figure 10 but with the liftable flap in raised position.

Figure 14 is a partial plan view of an alternative form of end closure.

Figure 15 is a fragmentary side elevation of the end closure of Figure 14 in the erected and closed position.

Figure 16 is a partial plan view of yet another form of closure blank made in accordance with our invention.

Figure 17 illustrates yet another form of blank in accordance with our invention.

Figure 18 is a fragmentary perspective view of the blank of Figure 17 in erected condition prior to the infolding of the outermost closure flaps.

Figure 19 is a plan view of still another carton blank in accordance with our invention.

Figure 20 is a perspective view with parts broken away of a procedure for applying pressure to crimp the edges of the container body Walls adjacent the top closure thereof.

Figure 21 is a fragmentary perspective view of the forming mandrel employed in Figure 20.

Figure 22 is a fragmentary side elevational view of the forming mandrel illustrated in Figure. 21.

Figure 23 is an elevational view illustrating diagrammatically the application of external pressure means to the end of the container and illustrating in dotted lines the manner in which the container is removed from the mandrel.

Figure 24 is a fragmentary perspective view illustrating the upper end of the container subsequent to its removal from the forming mandrel and prior to the infolding of the outermost closure flaps.

Figure 25 is a perspective view similar to Figure 24 but showing the forming members in contact with the upper end of the container.

Figure 26 is a fragmentary side elevational view of the container illustrated in Figure 25 in the closed position, pressure applying means being diagrammatically illustrated.

Referring'now to Figure l of the drawings we have therein illustrated a container blank comprising body walls 1, 2, 3 and 4 in articulation in the order named and a glue flap 5 connected to the free side edge of the body wall 4 for tubing the structure. Bottom closure fiaps 6, 7, 8 and 9 are provided on the bottom edges of the body walls. At its top the body wall 1 is provided with a full width outennost closure flap 10 having a liftable flap portion 11 formed therein, the liftable flap portion having projecting edges 11a and 11b extending beyond the corresponding edges of the closure flap 10.

The liftable flap portion is articulated to the flap along a line of score 12 diagonally disposed with respect to the side edges of the flap 10.

Narrow closure flaps or flanges 13, 14 and 15 are articulated, respectively, to the upper edges of the body Walls 2, 3 and 4, the narrow flanges being separated from each other by the triangular cutouts 16 and 17. A substantially full width intermediate closure flap 18 is hingedly articulated to the side edge of outermost closure flap 10 along the score line 19; and preferably the intermediate flap 18 will be severably connected to the narrow flange 13 along a line for severance 20. A pouring opening 21 is formed in the flap 18 adjacent a corner edge thereof in substantially the position shown. In addition, the body walls 2, 3 and 4 are provided with a continuous score line 22 paralleling the top edges of the body walls and spaced therefrom by a distance sufficient to define depressible or bendable wall portions 2a, 3a and 4a.

The blank Will be tubed by infolding the body walls 1 and 4 along the lines of articulation 23 and 24, respectively, thereby bringing the structure to the condition illustrated in Figure 3, it being understood that adhesive 25 will have been applied to the glue flap 5 prior to the infolding of the parts. This folding operation may be carried out on a conventional container gluing machine, the blanks being moved in a direction paralleling the lines of articulation 23 and 24. The line for severance 20 which serves to join the intermediate closure flap 18 to the flange 13 will maintain the closure flap in alignment with the remainder of the blank, which might not be the case were the closure flap 18 free to fold along the score line 19. In this connection, it will be noted that the line of articulation 19 is a prolongation of the line of articulation 23 and consequently the folding instrumentality used to infold the body wall 1 will concurrently infold the closure flap 10 and juxtapose it on the intermediate closure flap 18, in the manner illustrated in Figure 3.

Subsequent to tubing, the blank will be erected and placed over a mandrel with the bottom flaps 6, 7, 8 and 9 uppermost, whereupon the bottom closure flaps will be infolded and sealed across the end of the mandrel with the application of external pressure to the closure flaps. Sealing the bottom flaps in this fashion assures a positive and tight closure at the bottom of the container. The container, with its bottom end sealed, will then be removed from the mandrel and placed upright in a cage or upon other suitable conveying means for subsequent treatment of the top closure.

As the container is moved along in upright position, the outermost closure flap 10 and intermediate closure flap 18 will be jointly outfolded and supported from beneath on a plate, such as the plate 26 seen in Figure 4. The outfolding of the closure flap 10 will automatically disengage the closure flap 18 from the flange 13, the two members parting along the line for severance 20. Upon outfolding of the closure flaps, adhesive 27 will be applied to the exposed surface of closure flap 18 or to the mating surface of closure flap 10, whereupon the flaps will be elevated to the vertical position, as by means of a sweep 28. A folding bar 29 will engage closure flap 18 and fold it rearwardly onto closure flap 10 in the manner diagrammatically illustrated in Figure 4. Care must be taken in applying the adhesive 27 so that no portion thereof will contact the liftable flap portion 11 upon juxtaposition of the closure flaps. As illustrated in Figure 5 it is desirable to pass the juxtaposed closure flaps 10 and 18 between pressure rolls 30 and 31 to positively press the flaps together and assure a good bond between them.

Upon moving beyond the pressure rolls, the container will be contacted by an internal pressure member 32 (Figure 6) which travels with the container and is adapted to enter its upper end. External pressure members, such as the members 33 and 34, also travel with the container and coact with the recessed ledges, such as the ledges 35 and 36, of the internal pressure member to crimp or bend inwardly the upper end portions 2:: and 4a of the body walls 2 and 4, the body walls bending inwardly along the score line 22. At the same time the narrow flanges, such as the flanges 13 and 15, will be bent outwardly by the coaction of the pressure members to the position illustrated in Figure 7. It will be understood that the internal pressure member 32 will be configured on three sides, with a corresponding number of external pressure members, so as to also crimp inwardly the upper wall portion 3a of body wall 3 and concurrently fold outwardly the flange 14.

As can be best seen in Figures 7 and 8, the inward displacement of the upper edges of the body wall portions 2a, 3a and 4a is substantially equal to the width of the flanges 13, 14 and 15, thereby aligning the free edges of the flanges with the planes of the body walls. The free edges of the flanges are also aligned with the edges of the overlying full width closure flaps 10 and 18 so that subsequent infolding of these flaps will juxtapose their edge portions on the flanges. As seen in Figure 8, a peripheral stripe of adhesive 37 will be applied to the exposed undersurface of closure flap 18 whereupon the closure flaps will be infolded to bring their edge portions into adhesive contact with the narrow flanges.

As. best seen in Figure 9 the narrow flanges come together in mitered corners, the triangular cutouts 16 and 17 (Figure 1) acting tocut off the ends of the flanges to provide for the mitered fit.

It is desirable to seal the closure flaps 10 and 18 to the flanges under positive sealing pressure, and to this end supporting fingers, such as the fingers 38 and 39 (Figure 12) are provided to engage beneath the outturned flanges 13 and 15, whereupon an external pressure plate 40 may be brought to bear upon the upper surface of closure flap 10, thereby tightly sealing the parts together under positive pressure. While not shown, it will be understood that a similar finger will be provided to support the flange 14. When sealed in this fashion the resulting end closure is extremely sturdy and exceptionally tight. The outermost and intermediate flaps are positively sealed together and they in turn are posi tively sealed to the flanges which extend about the remaining sides of the container. The containers may be tightly packed in a shipping crate having no portion thereof extending beyond their body walls and at the same time, their recessed upper ends permit them to be readily gripped by the user.

Following the positive pressure sealing of the, end flaps in the manner described above, the carton will be proofed internally by means of castings of sealing substance formed across the ends of the container in the manner taught in the aforementioned copending application Serial No. 414,558, thereby providing, as illustrated in Figures 12 and 13, an interior end casting 41 bonded to the body walls and end of the container and including the severable plug portion- 42 bonded to the undersurface of the liftable flap portion 11 and adapted to break away from the body of the casting when the liftable flap portion 11 is raised. The subsequent closing of the liftable flap portion will cause the plug 42 to reenter the opening formed in the casting, thereby form ing a tight reseal for the container. When initially sealed, it will be understood that the extending edge portions 11a and 11b of the liftable flap will be folded or crimped about the adjacent edges of the flanges 14 and 15 to lock the liftable flap in the closed position.

In Figure 2, we have illustrated a modification of the container blank wherein the flanges 13, 14 and 15 are separated from each other by lines of cut 43 and 44 rather than by the triangular cutouts 16 and 17, as in Figure 1. While this eliminates the mitered fit of the flanges at the corners, we have found this construction to be wholly adequate, particularly where the flanges are relatively narrow and not likely to bunch at the corners.

While in the embodiment thus far described the upper ends of the body walls are bent inwardly so as to align the outer edges of the narrow flanges with the side walls of the container, it is also within the spirit of our invention to utilize the same flap construction in an end closure in which the narrow flaps extend outwardly beyond the body walls, thereby eliminating the necessity for crimping inwardly the top portions of the body walls. To this end, the container blank is constructed in the manner illustrated in Figure 14 wherein it will be seen that the full width closure flap 50 is provided with extending side edges 51 and 52 which effectively increase the width of the flap 50 beyond the cross sectional dimensions of the container body by a distance equivalent to the widths of the opposed narrow flanges 53 and 54 which the said extensions are adapted to overlie in the sealed structure. An intermediate full width closure flap 55 is provided having a pouring opening 56 therein; but since the line of articulation 57 connecting intermediate closure flap 55 to outermost closure flap 50 is offset laterally with respect to the line of articulation 23 connecting the body walls 1 and 2, the flap 55 is separated from the underlying flanges 53 and 58 by a line of cut 59. If closure flap 55 were detachably connected to the underlying flanges 53, the parts could not be folded on an ordinary folding and gluing machine since closure flap 55 must be free to move laterally as the body wall 1 is infolded along the line of articulation 23. I

When assembled the blank of Figure 14 will assume the condition illustrated in Figure 15 wherein it will be seen that the narrow flanges, such as the flanges 53 and 54, extend outwardly from the planes of the body walls to which they are attached and are contacted by edge portions of the intermediate closure flap 55. Similarly, the extending edge portions 51 and 52 of the outermost closure flap 5 0 overlie the extending flanges. It will be understood that a peripheral stripe of adhesive will be applied to the undersurface of closure flap 55 and the flanges will be supported from beneath by suitable fingers so that a pressure applying member similar to the member 40 (Figure 12) may be employed to press the parts together to effect a positive seal.

7 The blank illustrated in Figure 16 also contemplates the use of narrow flanges extending outwardly beyond the planes of the body walls, but in this instance flanges are provided on all four body walls, the body wall 1 being provided with a flange 61 and outermost closure flap 50 with an extension 62 to compensate for the width of the flange. Preferably the intermediate flap 55 will be articulated both to the flap 50 and to the extension 62 in the manner illustrated. It will be understood that this end closure will be folded and seated in substantially the same manner as the end closure of Figure 14 excepting supporting fingers will be provided for all four flanges.

Figure 17 illustrates a modification of the blank illustrated in Figure 1 wherein the body wall 1 is provided with a flange 63 and a continuation of the score line 22 defining body Wall portion 1a, thereby providing a structure having flanges on all four sides in which the outermost edges of the flanges are in alignment with the body walls. It will be understood that the width of the outermost flap will be increased by an amount equal to the width of the flange 63 to compensate for the width of the flange. Pressure exerting means will be provided, similar to those illustrated in Figure 12, for supporting the flanges during the application of sealing pressure to the outermost flap.

Figure 18 illustrates the top closure formed from the blank of Figure 17 just prior to the infolding of the full width flaps and their adhesive attachment to the outturned narrow flanges.

In Figures 19 through 26, we have illustrated yet another form of container blank and its fabrication into a completed container. The blank corresponds 'sub-' stantially to the blank illustrated in Figure 2 excepting in this instance the score line 22 is omitted, the inward deflection of the upper edge portions of the body walls being solely by means of the pressure members hereinafter described. As best seen in Figures 20 and 21, the blank, after it has been tubed, is fitted top downwardly over a mandrel 70 having a flat upper end over which the bottom closure flaps may be folded and sealed, as by means of a pressure plate 71. At its lower end the faces of the mandrel contacted by body walls 2, 3 and 4 are recessed, as at 72, 73 and 74, the recessed portions being arranged, as best seen in Figure 22, to coincide with the upper ends of the body walls. Thus the upper ends of the body walls may be crimped or deflected inwardly into the recesses by means of external pressure members 75, 76 and 77 seen in Figure 20. These external pressure members also act to fold the narrow flanges outwardly in the manner best seen in Figure 23.

Subsequent to the container being acted upon by the external pressure members 75, 76 and 77, it may be thereafter withdrawn from the mandrel, the resiliency of the boxboard serving to permit ready withdrawal of the inwardly deflected end portions thereof. Upon being uprighted, the upper end of the container will then be acted upon by external forming members 78, 79 and 80 which will serve to press inwardly the initially deflected portions of the body Walls to bring them into proper position to be contacted by the full width closure flaps. The initial deflecting of the body walls while on the mandrel enables us to employ the external forming members 78, 79 and 80 without using an internal pressure member, such as that employed in Figures 6 and 7. In addition, the external forming members 78, 79 and 80 may be used, when in the position illustrated in Figure 25, to support the narrow flanges during the pressure sealing of the outermost flaps thereto, as by means of the pressure plate 81 shown in Figure 26. We have also found it desirable to cut away a small portion of the body wall 1 adjacent its upper end, as at 82 (Figure 19). This acts to compensate for the extra thickness of board at the corner resulting from the glue flap 5. This extra thickness of board makes it more diflicult to crimp in the corner of the carton and the cut out portion 82 relieves this condition.

It will be understood that internal end castings of sealing substance may be employed with any of the modifications described or may be omitted as the conditions of use may dictate. Similarly, while we have indicated a preferance for securing the various flaps and flanges making up the end closures by means of adhesive, it will be understood that the boxboard from which the containers are formed may be provided with a vinyl or other similar coating which will render the parts heat scalable, in which event the pressure applying means may be provided with suitable heating means effective to heat seal the flaps. Other modifications which will be apparent to the skilled worker in the art upon reading this specification, may be made without departing from the spirit of our invention.

Having, however, described our invention in certain exemplary embodiments, what we desire to secure and protect by Letters Patent is:

l. A method of acting upon containers which comprises providing a knocked-down container having a tubular body and end closure means, the closure means at one end of the container comprising a plurality of flaps adapted to be folded in supenposed relation, and at the other end comprising a plurality of narrow flanges adapted to be folded outwardly relative to the body walls of the container, erecting said container and positioning it over a mandrel with said first named end aligned with an end of the mandrel, sealing the closure flaps at said first named end over the said end of the mandrel, and while said container is supported on said mandrel, acting upon the opposite end of the carton to crimp inwardly the porttions of the carton body walls adjacent the said narrow flanges, including the step of folding said narrow flanges outwardly at substantially right angles to the planes of said body walls.

2. The method claimed in claim 1 wherein the last named'end of said container includes a full width closure flap, and including the steps of removing the container from the mandrel, infolding said full width closure flap and adhesively securing it to the said outturned flanges.

3. The method claimed in claim 2 including the step of pressing the deflected portions of the container body walls inwardly subsequent to the removal of the container from said mandrel so as to align the said flanges with marginal portions of the said full width closure flap.

4. A method of sealing together all of the end closure flaps at both ends of a container under positive sealing pressure applied throughout the entire contacting areas of the flaps being joined, which comprises providing a knocked-down container having a tubular body and end closure means at the ends thereof, the closure means at one end of said container body comprising a plurality of flaps adapted to be folded in superposed relation, and at the other end comprising at least three narrow flanges connected to the end edges of three of the container body walls and adapted to be folded outwardly, a first full width closure flap articulated to the end edge of the remaining container body wall and adapted, when infolded, to overlie said outfolded flanges, and a second full width flap articulated to a side edge of said first full width flap adjacent the edge thereof articulated to said remaining container body wall, erecting said container body and sealing the first named end thereof over a mandrel including the application of positive sealing pressure to the external surfaces of said superposed flaps, folding said first and second full width closure flaps into face-to-face contacting relation and sealing said flaps together between pressure applying surfaces, and thereafter infolding the said sealed together full width flaps and securing them to the outturned narrow flanges, including the step of supporting the said narrow flanges from their undersides and applying positive sealing pressure to the top surface of said secured together full width closure flaps, the steps of infolding the said sealed together full width flaps and the sealing thereof to said narrow flanges occurring subsequent to the removal of said container from the mandrel.

5. The method claimed in claim 4 including the step of crimping inwardly end portions of the container body walls adjacent said narrow flanges and folding said narrow flanges outwardly with respect to the planes of the body walls to which they are secured while said container is supported on the mandrel.

6. A method of sealing together all of the end closure flaps at both ends of a container under positive sealing pressure applied throughout the entire contacting areas of the flaps being joined, which comprises providing a container having a tubular body and end closure means at the ends thereof, the closure means at one end of the container comprising a plurality of flaps adapted to be folded in superposed relation and at the other end comprising at least three narrow flanges connected to the end edges of three of the container body walls and a full width closure flap hingedly connected to the end edge of the remaining container body wall, erecting said tubular body and positioning it over a mandrel with the first named end in alignment with an end of the mandrel and with the said narrow flanges in registry with recesses in the underlying Walls of the mandrel, sealing the closure flaps at the first named end of the container over an end of the mandrel under positive sealing pressure applied to the external surfaces of the said flaps, and while the container is supported on said mandrel, deflecting said flanges and the adjoining end portions of the carton body walls into the recesses so as to crimp inwardly the end portions of said container body walls and, as the said end portions of the container body walls are being deflected inwardly, folding said narrow flanges outwardly so as to pre-break them along their lines of connection to said container body walls, thereafter removing the container from said mandrel, and infolding and securing said full Width closure flap to said narrow flanges, including the step of pressing said full width closure flap and said flanges together between compressing surfaces effective to seal them together under positive sealing pressure.

7. The process claimed in claim 6 wherein a second full width closure flap is hingedly connected to a side edge of said first named full Width closure flap, and wherein said two full width closure flaps are sealed together in face-to-face contacting relationship between compressing surfaces prior to the infolding and securing of said first named full width closure flap to said narrow flanges.

8. A method of sealing together the end closure flaps of a container under positive sealing pressure applied throughout the entire contacting areas of the flaps being joined, which comprises providing a container having enclosing body walls and an end closure composed of three narrow flanges hingedly connected to the end edges of three of the container body walls, a full width closure flap hingedly connected to the end edges of the remaining container body wall, and a second full width closure flap hingedly connected to a side edge of said first named full width closure flap, first folding said two full width closure flaps in face-to-face contacting relation and sealing them together between compressing surfaces under positive sealing pressure, thereafter infolding said secured together full width closure flaps and juxtaposing them to said narrow flanges, including the step of outfolding said narrow flanges prior to the infolding of said secured together full width closure flaps, and sealing together said secured together closure flaps and said flanges between compressing surfaces contacting respectively the undersides of said flanges and the top surface of said secured together closure flaps.

References Cited in the file of this patent UNITED STATES PATENTS 751,714 Brooks Feb. 9, 1904 1,954,428 Richard Apr. 10, 1934 2,549,048 Bergstein Apr. 17, 1951 2,596,225 Eaton May 13, 1952 2,663,981 Sanford Dec. 29, 1953 

